Method of manufacturing industrial textiles by minimizing warp changes and fabrics made according to the method

ABSTRACT

A method of weaving industrial textiles to a single warp platform, and textiles made thereby. The method comprises identifying optimal fabric characteristics for selected uses to determine groups of suitable fabrics; selecting a first group, identifying fabric properties for optimal characteristics, and identifying optimal properties for warp yarns to be used for all fabrics in the group; selecting a structure type and weave design for each fabric of the group; providing a loom with selected shedding options and installing warp yarns having the identified optimal properties. Thereafter, each fabric in the group can be woven without changing the warp yarns, simply by identifying properties for weft yarns to correspond with the weave design of the respective fabric, setting the loom accordingly and weaving the fabrics as required, adjusting only the weft parameters between successive fabrics, resulting in increased efficiency of manufacturing and avoiding time consuming warp changes between fabrics.

FIELD OF THE INVENTION

This invention relates to the manufacture of industrial textiles, and inparticular to a method of operating looms in such manufacture and tofabrics produced according to the method. More particularly, theinvention relates to a method of improved manufacturing of such textilesby reducing the number of different meshes (number of warp yarns perunit width of fabric across the loom, e.g. yarns/in. or yarns/cm) andwarp yarn sizes required, and thus the number of warp yarn changesrequired for such looms to produce in sequence a number of differentfabrics each having similar properties to those of fabrics previouslywoven at differing meshes and using differing warp yarn sizes, so as tothereby minimize the idle time, or down time, of looms.

BACKGROUND OF THE INVENTION

Industrial fabrics such as are used in papermaking, filtration and likeapplications are generally woven structures made using very wideindustrial looms which can be 30 ft. (10 m) in width or wider. Certainof these fabrics, particularly those used in papermaking to initiallyform and drain the sheet (referred to as forming fabrics), arefrequently woven at very high mesh counts, meaning that the number ofwarp yarns per unit of fabric width is relatively high in comparison toother papermaking fabrics, and can be in the range of up to 200 yarnsper inch (78.7 yarns/cm) or more. These yarns can be very small in size,with diameters ranging from as low as about 0.08 mm or less up to about0.30 mm or more; other fabrics, such as those used in the press or dryersections of papermaking machines, or in similar industrial filtrationapplications, may have warp yarn sizes in the range from about 0.3 mm upto about 0.7 mm or higher. These larger yarns are frequently woven toprovide a mesh of from 20 yarns/inch (7.87 yarns/cm) up to about 70yarns/inch (27.6 yarns/cm). Selection of appropriate weave designs forthese industrial fabrics, and selection of warp and weft yarn diametersand cross-sectional shapes for use in these industrial fabrics isgenerally based on the type of product to be made, the environment inwhich the fabric is to be used, and characteristics of the machine forwhich the fabric is intended.

The features of the present invention are particularly applicable topapermakers fabrics, and most particularly to papermakers formingfabrics, but are also applicable to many other types of industrialfabrics used for various filtration purposes. In the followingdiscussion, references to papermakers fabrics, or to papermakers formingfabrics, can generally be understood as including such other types ofindustrial filtration fabrics.

Industrial fabrics such as papermakers forming fabrics are currentlywoven to provide one of the following well-known textile structures:

-   -   a. Single layer fabrics, woven using one warp yarn system and        one weft yarn system;    -   b. Semi duplex fabrics, woven with one warp yarn system and two        layers of weft yarns, which yarns are not stacked directly over        each other;    -   c. Double layer fabrics, woven with one warp yarn system and two        layers of weft yarns which are arranged so that each weft yarn        in the top surface is vertically stacked so as to be directly        above a corresponding weft yarn in the lower surface;    -   d. Extra support double layer fabrics, similar to double layer        fabrics but with additional weft yarns woven into the top        surface;    -   e. Triple weft fabrics, woven using one warp yarn system and        three weft yarn systems arranged so that the weft yarns are        vertically stacked over each other;    -   f. Standard triple layer fabrics, woven using two warp yarn        systems and two weft yarn systems to provide two independent        fabric structures which are frequently tied together during        weaving by means of an additional weft yarn system;    -   g. Triple layer sheet support binder (SSB) fabrics, woven using        two systems of warps and two systems of weft yarns; a selected        number of the weft are woven into the fabric as exchanging,        interchanging yarn pairs so that as one yarn of the pair is        being woven into e.g. the top surface the other is woven into        the bottom;    -   h. Triple layer “warp tie” fabrics, woven using two weft (CD)        yarn systems and two warp (MD) yarn systems; at least a portion        of the warp yarns are woven as interchanging pairs so that as        one yarn of the pair is being woven into e.g. the top surface        the other is woven into the bottom; in certain designs, some of        the warp yarns of each of the two systems will be interwoven        exclusively with weft yarns of one of the top or bottom systems        of weft yarns;    -   i. Triple layer warp integrated sheet support binders (WISS),        woven using two weft (CD) yarn systems and two warp (MD) yarn        systems in which all (100%) of the warp yarns are woven as        interchanging pairs so that as one yarn of the pair is being        woven into e.g. the top surface the other is woven into the        bottom.

Papermakers forming fabrics are currently manufactured using carefullyselected yarn sizes and materials which, when woven to provide one ofthe above textile structures, with a chosen mesh and knock (number ofweft yarns per unit length of fabric, e.g. yarns/in. or yarns/cm), areintended to best suit the grade or type of product that is to bemanufactured on a specific papermaking machine having unique performancecharacteristics. Each papermaking machine and each type of stock (thatis, the highly aqueous mixture of water, papermaking fibers andchemicals) have, in combination, a unique set of operating parameterswhich the papermaking fabric manufacturer will strive to accommodate soas to optimize the quality of the paper product to be made. In addition,the fabric itself must be extremely rugged and provide a stablestructure which will withstand, without distorting or catastrophicallyfailing, the speeds and environmental conditions in which it is expectedto operate.

The fabric surface upon which the papermaking fibers are deposited,referred to as the paper side or PS, must be constructed so as touniformly support the fibers and form the sheet, while providingadequate drainage of fluid from the papermaking stock deposited thereon.The opposite fabric surface, referred to as the machine side or MS, mustbe rugged and dimensionally stable so as to provide a secure and robustbase below the fine papermaking surface. While in operation, the fabricwill be running in an endless loop through the papermaking machine atspeeds as high as 1,500 m/min or more and will be in moving contact withvarious stationary dewatering devices (such as blades, foils and suctionbox covers) in the machine.

Given these differing requirements, either for the two surfaces of asingle layer fabric or the different layers of other fabric types, thefabric manufacturer must strike a balance between the papermakingproperties (e.g.: fiber support and drainage capabilities of the PSlayer), and the mechanical properties of the fabric (e.g.: elasticmodulus, shear stability, caliper and seam strength) while providing atextile product which is suitable for the manufacture of a particulargrade of paper on the machine for which it is intended. In the past,this was frequently done by changing one or more of the fabric mesh,knock, yarn size and structure.

Woven industrial textiles are typically manufactured from polymericmonofilament or multifilament yarns as each of the warp and weftmaterials. During weaving, the warp is paid off from a yarn supply atthe back of the loom (from what is referred to as a back beam), passedthrough reed openings mounted in the loom heddles, and then around atake-up roll at the front of the loom. As the heddles are moved up anddown, the individual warp yarns are thus moved to create so-called shedopenings. The weft yarns are shot, or carried, across the shed openingsfrom one side of the fabric to the other by means of a shuttle, rapieror similar mechanism, depending on the loom type. These weft yarns arepaid off from a storage canister or bobbin located at each side of thefabric. The weave pattern of the fabric is created by controlling themovement of the heddles and thus the individual warp yarns so thatselected ones are positioned either above or below a specific weft yarn,thereby creating interlacing locations across the width of the fabric.

Changes to the weft yarn size and knocking are easily made by canisterchanges and frequently such changes are an integral part of the fabricmanufacturing process. However, warp yarn changes are much moredifficult and time consuming to make, particularly on wide industriallooms such as those used for the manufacture of papermaking fabrics, asthey require changing one or both of the back beam and the heddles, andre-threading of each of the thousands of individual warp yarns throughboth the heddles and reeds.

Industrial fabric manufacturers typically wind thousands of feet ormeters of warp yarn onto large individual spools (referred to as “cans”)which are about 3 ft (1 m) in diameter and range from about 4 to 12inches (10 cm to 30.5 cm) in width. These cans are usually made of steelor a similar rugged material and, when full of yarn (which has beencarefully wound onto the can at predetermined tension) they are thenmounted in succession along the back beam of the loom to provide thesupply of warp material for the fabrics that are to be woven. Forexample, a 10 m wide loom equipped with 4 inch (10.2 cm) wide cans mighthave more than 100 of such cans mounted in succession along its backbeam. If the loom is a double beam loom, meaning it is equipped with twosuch back beams, then the number of cans would be double that of asingle beam loom, or 200 such cans or more.

Warp changes on a loom, other than for replenishment, are typically madeto accommodate fabrics having either different textile structures ormeshes, or both, than those made previously on the same loom. The warpchange will usually be made to allow the manufacturer to weave otherfabrics having differing mechanical properties and constructions fromthose previously produced. For example, a warp change would be made toallow the production of a fabric with a different mesh, or larger orsmaller warp yarn sizes than previously used, or yarns having adifferent cross-sectional shape, or made from a different material, thanwas previously made on the same loom. Alternatively, a warp change willbe made when the manufacturer wishes to weave a different textilestructure on the same loom previously used to weave another structure(e.g. a triple layer fabric where previously a semi-duplex fabric waswoven). Such changes are usually made to produce a fabric which isoptimized for its intended end use, whether for papermaking propertiesor mechanical properties. Because of the difficulties associated withchanging the warp material or the fabric mesh, fabric manufacturers willfrequently devote one or more looms to a particular warp size and fabrictype or structure, and will then carefully schedule fabric production sothat the same loom is devoted to making as many of that style using thatsame warp as are required before a further and very time consuming warpchange is necessary.

A simple warp change (that is, a material replenishment that does notrequire a mesh change) is effected as follows when there is no fabricstructure change. The original warp yarns are cut before (i.e. on thecan side of) the heddles so as to leave trailing ends, and the canscontaining the old warp material are removed from the back beam; canscontaining the new warp material are then mounted onto a new or theexisting back beam at the back of the loom. The old beam or cans areremoved from the loom and the new beam or cans are then suitablypositioned. The trailing ends of the existing warp yarns are then joinedonto those from the new beam and the loom is advanced (i.e. the take-uproll is advanced so that the existing warp is wound onto it) and theyarns from the new beam are passed through the heddles following theprevious ones. Weaving can then re-commence once all of the new yarnsare in position and placed under suitable tension. This relativelysimple change can be executed quickly compared to a complete warp andmesh change.

However, when the warp change is required due to a fabric mesh change,or warp material change, or the number of sheds required to weave thenew fabric is different from that needed to weave the previous fabric,or if the new fabric has a different structure (i.e. single layer,double layer, triple layer, etc.) from that previously woven, then theloom must be completely re-drawn or re-threaded, meaning that the oldwarp must be removed and the new warp must be individually and manuallythreaded through the eyelets of each of the heddles. It will beappreciated that when 100 or more warp yarns/inch (39/cm) must bethreaded through the heddles of a loom used to produce a 10 m widefabric, this threading can be a very time consuming process. Other loomcomponents may also need to be changed. Following the warp change, theloom must then be re-set so as to establish appropriate weaving tensionsand other parameters, which will allow the manufacturer to produce afabric according to the required specifications. Depending on the widthof the loom and the warp yarn size, this entire process can remove theloom from production for several weeks and require the assistance ofnumerous skilled employees; while re-threading is occurring, the loom isunable to produce any fabric. It will thus be appreciated that a warpchange can be a very expensive and time consuming process.

The as-woven fabric mesh, warp diameter, material and cross-sectionalshape, together with the number of sheds on the loom required to weavethe fabric, are collectively referred to as a “warp platform”; a warpplatform specifies all of the requirements needed to specifically definethe warp of the fabric to be woven.

Efforts have been made by various loom and textile manufacturers toreduce the time taken for performing the conventional warp changingprocess, by improving the efficiency of steps within the process.Examples of attempts to address the mechanical aspects of the steps inwarp changing include U.S. Pat. No. 6,314,628 to Crook; U.S. Pat. No.7,178,558 and U.S. Pat. No. 7,318,456 both to Nayfeh et al.; U.S. Pat.No. 5,775,380 to Roelstraete et al.; U.S. Pat. No. 5,394,596 and EP592807 both to Lindenmuller et al.; and U.S. Pat. No. 4,910,837 toFujimoto et al.

However, none of these disclosures address the distinct and fundamentalissue of the disadvantages of the frequency at which complete warpchanges are required. It would therefore be highly desirable to avoid orsignificantly reduce the need to make such changes, thereby reducingproduction costs while increasing efficiency, while continuing to allowfor the manufacture of a wide range of industrial textile products, andaccommodate a variety of fabric meshes, structures and designs.

It has now been found that this desired reduction in the frequency ofwarp changes, in comparison with present practice, can be achieved byestablishing a warp platform which is compatible with the parameters fora variety of fabric products, and making adjustments to the parametersfor the weft yarns, resulting in the ability to weave a variety ofdifferent fabrics in succession, each having properties and designsequivalent to those of selected fabrics of different types, without anyneed for the warp changes which would previously have been required forweaving those various fabric types in succession.

SUMMARY OF THE INVENTION

Conventionally, industrial textile manufacturers have diversified thenumber of warp sizes, meshes, materials and cross-sectional shapes usedto make fabrics for their customers in the belief that, in this manner,the fabrics could be optimized for the grade of product to bemanufactured and the machine for which the fabric was intended.

It has now been found that fabric manufacturers have unnecessarilyover-diversified their production in the past, and have been producingfabrics within the same design “family” (e.g. double layer, triplelayer) which may utilize a warp yarn size difference of as little as0.02 mm, using differing meshes, for different applications orcustomers, i.e. two fabrics within the same design would conventionallybe manufactured on different looms employing differing meshes and warpyarns whose diameter differed by as little as 0.02 mm so as to meetcustomer-specific or basis weight requirements. The invention is thuspredicated on the understanding that there are more warp sizes in usethan are justified by the difference in basis weight and other paperproperties between the products being manufactured using the fabrics.

It has now been found from recent experience and experimentation that itis possible to accommodate almost all papermaking (and similar fabric)requirements by reducing the number of warp meshes, yarn sizes, andcross-sectional shapes (warp platforms) to as few as one, but no morethan four types, thus minimizing the number of different warp platformsused to weave the fabrics and thus the number of warp changes requiredto produce fabrics adequate to meet almost all of those needs.

Whereas in the past it was necessary to have, for example, as many asten looms (and warp size and mesh combinations) or more, each devoted tothe production of a single product having a specific design and mesh soas to minimize warp changes on the individual looms, it is now possibleby means of the present invention to reduce the number of warp changessignificantly, generally to no more than four, and possibly as few asone, depending on the papermaking and mechanical requirements of thetextile products to be made. This rationalization process is describedherein as a “single warp platform” (SWP) approach, meaning that theweaving parameters for all fabrics previously made, and new fabricscompatible therewith, and previously using a variety of warp sizes andmeshes, can now be modified so that the warps can be selected from nomore than four configurations, and preferably as few as three.Adjustments to fabric properties are then made by selection of any orall of the weft yarn parameters of size, shape, material and density(knocking) prior to and during weaving as well as the subsequent fabricprocessing parameters, such as heatsetting and tensioning.

Pursuant to the invention, a single loom can be provided for each of oneor more chosen warp platforms, each including yarns having a specifiedcomposition, cross-sectional shape and size, threaded to a chosen mesh.Each one can then be used to weave a group of fabrics, the differentgroups having differing structures, each of which is intended for use inthe production of paper products of differing grades or having differingbasis weights. In order to do this, one or more of the weft yarn size,cross-sectional shape, polymer composition and knocking is adjusted inthe design of the fabric (in comparison to a corresponding substantiallyequivalent known fabric), or provided in new designs for fabrics in thespecific group, so as to provide a textile product with both comparablepapermaking properties including drainage area, fiber support, framelength and air permeability, and mechanical properties including elasticmodulus, shear stability and stiffness sufficient to accommodate theproduction of paper products having differing basis weights. The fabricswoven using the warps on that one loom will, of necessity, all have thesame mesh in each of the PS and MS layers and will be woven using thesame number of sheds in the loom. In the case of a single layer fabric,the set of warp yarns can be divided into two groups, to weave upper andlower fabrics, each of which would have one-half the mesh of theprevious single layer fabric. Adjustments to physical properties arethen made by changing the weft yarn material and subsequentheatsetting/processing parameters.

The invention seeks to provide a method for optimizing industrial fabricproduction, and fabrics produced by the method, comprising reducing orminimizing the number of times the warp yarn material on a loom must bechanged, by providing a manufacturing method whereby a number ofdifferent textile products, having some equivalent or closely relatedcharacteristics, can be made in sequence using the same loom and warpplatform, thus minimizing the number of warp changes necessary betweenproduction of the different fabrics, in comparison to the presentpractice. At the same time, the physical characteristics of the fabricscan be selected to closely match the requirements necessary for the endconsumer to manufacture a range of cellulosic products whose basisweights range from at least 15 to 80 gsm (grams per square meter) ormore.

The fabrics of the invention comprise groups of at least two industrialfabric structures, each of which is woven using the same warp platformincluding polymeric warp yarns of the same composition, size,cross-sectional area and shape, and each of which is woven to the samemesh. A group of industrial fabrics produced in accordance with themethod of optimizing industrial fabric production can include any two ormore of the following textile structures: single layer fabrics, semiduplex fabrics, double layer fabrics, extra support double layerfabrics, triple weft fabrics, standard triple layer fabrics, triplelayer sheet support binder (SSB) fabrics, triple layer warp tie fabrics,and triple layer warp integrated sheet support binders (WISS). Eachfabric in a group of fabrics of the invention will include warp yarnshaving the same polymeric composition, cross-sectional shape and area,and number of yarns per unit of CD fabric width as the other fabrics inthe group. In textile structures which include in their constructionstwo layers of warp yarns, in particular double layer fabrics, extrasupport double layer, standard triple layer, triple layer sheet supportbinder (SSB), triple layer warp tie fabrics, and triple layer warpintegrated sheet support binders (WISS), the warp yarn cross-sectionalshape, size, material composition and mesh used in each layer will besubstantially the same.

The invention therefore seeks to provide a method of manufacturing wovenfabrics from warp yarns and weft yarns for industrial uses, the methodcomprising the steps of:

(a) identifying optimal fabric characteristics to correspond with atleast one selected industrial use to determine at least one group offabrics suitable for each selected industrial use;(b) selecting a set of shedding options for a loom and providing theloom with a shedding arrangement to provide the selected options;(c) selecting a first group of fabrics and identifying selected fabricproperties to produce the optimal fabric characteristics for the firstgroup of fabrics;(d) identifying optimal properties for warp yarns for the first group offabrics;(e) selecting a fabric structure type and a weave design for each fabricof the first group;(f) installing warp yarns on the loom to correspond with the optimalproperties identified in step (d);(g) selecting a first fabric of the first group, identifying propertiesfor weft yarns to correspond with a first weave design for the firstfabric, setting the loom to correspond with the first weave design, andweaving the first fabric according to the first weave design; and(h) selectively repeating step (g) for selected other ones of thefabrics in the first group.

Two or more fabrics made according to the manufacturing method hereindisclosed will have the same mesh as woven, and will include warp yarnsof the same composition, size and warp yarn cross-sectionalconfiguration regardless of the chosen fabric structure. Further, infabrics having two layers of warp yarns in their structure, the warpyarn size and mesh used in each layer will be substantially the same.

In such fabrics having two warp layers, when considered in relation tocomparable fabrics of the prior art, the PS warp diameter will belarger, while the MS warp diameter will be smaller than was typicallyused. This usage seems to be counterintuitive to traditional formingfabric design which taught that smaller PS warp yarns were required toprovide the necessary PS open area for drainage and fiber support, whilerelatively larger MS warp yarns were required to provide the necessaryelastic modulus to the fabric. While it is still necessary to provideadequate drainage area and elastic modulus in the fabric, it has nowbeen found that it is possible, by judicious and reasoned selection ofthe warp size used in each of these layers, to employ warp yarns of thesame diameter or cross sectional area in both the PS and MS layers, andto adjust other parameters in the weave design to address the problemspreviously encountered in attempting to use warp yarns of the same sizein the two layers. By doing so, the PS warp yarns will be increased indiameter in comparison to previous practice, while the MS warp size willbe decreased in size. The relatively larger PS warp will tend to closeup the drainage openings in the PS surface, while smaller MS warp willopen up the MS fabric structure. It has now been found that doing sodoes not appreciably affect drainage of fluid through the fabric, as theupsizing of the PS warp is balanced or offset by the downsizing of theMS warp. Further, while making the PS and MS warp the same size, it hasbeen found that by appropriate selection of that size in relation tovarious other properties, elastic modulus of the fabric can be eithermaintained or only slightly diminished.

In the method of the invention, preferably the identifying optimalproperties in step (d) comprises the steps of

-   -   (d.1) identifying optimal warp yarn sizes for the intended end        use;    -   (d.2) determining fabric mesh;    -   (d.3) determining cross-sectional shape and size of the warp        yarns;    -   (d.4) determining total warp cross sectional area per unit width        of the fabrics; and    -   (d.5) determining paper side warp fill.

Preferably, identifying the properties for weft yarns in step (g)comprises determining weft yarn size and knocking measured as number ofweft yarns per unit length of the fabric.

Preferably, step (b) comprises providing a loom equipped with a numberof back beams selected from one, two and three; and generally the loomwill be equipped with two back beams.

Preferably, the warp yarns are constructed of a material selected frompolyethylene terephthalate (PET), polyethylene naphthalate (PEN),polyetheretherketone (PEEK), polyphenylene sulphide (PPS) and blends andcopolymers thereof.

Preferably, the weft yarns are constructed of a material selected fromPET, polybutylene terephthalate (PBT), a polyamide selected frompolyamide 6, 6/6, 6/10, and 6/12, and blends of thermoplasticpolyurethane and PET.

Generally, step (a) comprises determining a maximum of four groups offabrics.

Preferably, the identifying properties in step (g) comprises selectionof adjustable properties selected from at least one of weft yarnmaterial, cross-section shape, size and knocking; more preferably, theselection of adjustable properties is performed to correspond withproduct criteria for a paper product to be manufactured using the firstfabric, wherein the product criteria comprise at least one of the basisweight and the paper grade of the paper product.

Preferably, the identified optimal properties for warp yarns compriseswarp sizes in ranges between 0.08 mm and 0.50 mm, and more preferablybetween 0.1 mm and 0.35 mm.

The step of selecting a weave design in step (e) can comprises modifyingan existing design, or preparing a new design.

Preferably, the shedding options in step (b) comprise using an integermultiple of 2, 3, 4, 6, 8, 12 or 24 sheds on the loom, and morepreferably the shedding arrangement requires 24 sheds.

Preferably, the selecting fabric structure type of step (e) comprisesselecting a type from single layer fabrics, semi-duplex fabrics, doublelayer fabrics, extra support double layer fabrics, triple weft fabrics,standard triple layer fabrics, triple layer sheet support binderfabrics, triple layer warp tie fabrics, and triple layer warp integratedsheet support binder fabrics, and more preferably from extra supportdouble layer fabrics, triple layer sheet support binder fabrics, triplelayer warp tie fabrics, and triple layer warp integrated sheet supportbinder fabrics.

Optionally, the selecting a weave design of step (e) comprises selectinga design requiring two systems of warp yarns, wherein the warp yarnmaterial, size, cross-sectional shape and mesh in each system issubstantially the same.

Preferably, the warp yarns are polymeric monofilaments; alternativelythey can be polymeric multifilaments, and optionally in either case theycan be plied or cabled. However, in general, single monofilaments arepreferred for use in the papermaking fabrics made in accordance with theteachings of this invention.

Preferably, the paper product is selected from a member of one of threegroups of paper products, wherein a first group has a basis weight in arange between 15 and 35 gsm, a second group has a basis weight in arange between 35 and 80 gsm, and a third group has a basis weightgreater than 80 gsm. Alternatively, the paper product is selected from amember of one of three groups of paper product grades, wherein a firstgroup comprises towel and tissue, a second group comprises printing andwriting, and a third group comprises packaging and linerboard.

Preferably, the size of the PS weft yarns is in a range of between 0.08mm and 0.50 mm, and more preferably between 0.1 mm and 0.35 mm.

Preferably, the PS weft yarns are polymeric monofilaments; alternativelythey can be polymeric multifilaments, and optionally in either case theycan be plied or cabled. However, the PS weft yarns should be compatiblewith the warp yarns, and in general, as for the warp yarns, singlemonofilaments are preferred for use in the papermaking fabrics made inaccordance with the teachings of this invention.

Preferably, the warp yarns have a diameter which exceeds a diameter ofthe PS weft yarns by less than 0.10 mm, and more preferably by less than0.05 mm.

Optionally, the method further comprises after step (g) the step of(g.1) heatsetting the first fabric.

The invention further seeks to provide a group of at least twoindustrial textiles, wherein each industrial textile comprises a wovenstructure of polymeric warp and weft yarns, wherein

(i) the warp yarns have warp yarn properties comprising size, shape,polymeric composition, and together have a mesh value; and(ii) the warp yarn properties and mesh value of each industrial textileare substantially identical to the warp yarn properties and mesh valueof each other industrial textile in the group.

Preferably, the woven structure of each industrial textile is selectedfrom one of a single layer, semi duplex, double layer, extra supportdouble layer, triple weft, standard triple layer, triple layer sheetsupport binder, triple layer warp tie, and triple layer integrated sheetsupport binder fabric construction.

Preferably, the composition of the warp yarns comprises polyethyleneterephthalate (PET), polyethylene naphthalate (PEN),polyetheretherketone (PEEK), polyphenylene sulphide (PPS) and blends andcopolymers thereof.

Preferably, each industrial textile is woven according to a patternhaving a loom requirement for a number of sheds selected from an integermultiple of 2, 3, 4, 6, 8, 12 and 24. However, the industrial textilescan be woven according to patterns having a loom requirement for theless usual numbers of sheds, such as selected from an integer multipleof 5, 7, 9, 11, 13, 17, 19 and 23.

Fabrics made in accordance with the teachings of this invention can bemade on a loom equipped with one, two or more warp beams. In instanceswhere the weave design of the MS of the fabric differs substantiallyfrom that of the PS, it may be necessary to weave the fabric using a twoor three beam warp configuration due to the differing path lengths ofthe warp yarns in each of the PS and MS layers.

By means of the present invention, a process is now provided whereby itis possible to manufacture in succession, using one loom provided withthe same warp platform, any of the known fabric constructions includingsingle layer fabrics, double layer fabrics, extra support double layer,standard triple layer, triple layer sheet support binder (SSB), triplelayer warp tie fabrics, and triple layer warp integrated sheet supportbinders (WISS), without having to make a warp change. By means of theprocess, it is now possible for each of these constructions to beoptimized, by adjusting one or more of the weft yarn size, knocking, orother process parameters, in particular the heatsetting process, so asto provide the desired mechanical and papermaking qualities in the finalproduct allowing it to replace an equivalent product which is notcreated according to the inventive method.

BRIEF DESCRIPTION OF THE DRAWING

The invention will now be described in relation to the drawing, in which

FIGS. 1A to 1C together comprise a flow chart of the steps in anembodiment of the method of the invention.

DETAILED DESCRIPTION OF THE INVENTION

The invention provides the important advantage that all, orsubstantially all, fabrics presently manufactured from a multiplicity ofdiffering warp types, each having differing warp yarn materials,cross-sectional shape or areas, or mesh from the other, and targeted fora generic paper grade (e.g. tissue and towel, printing and writing,packaging and linerboard) can now be made using a minimal number,possibly only one, warp platform, whose yarn size (i.e. diameter, forsubstantially circular yarns) is selected from the range of from 0.08 mmto about 0.50 mm such as would be optimal for a range of these textileproducts. Selection of a specific warp yarn size and mesh is determinedprimarily by the basis weight of the products to be manufactured, andcharacteristics of the papermaking machine for which the fabric isintended. It has also been found that fabric production can be furtherdiversified by warp yarn size and intended use as determined by thebasis weight of the product to be manufactured as shown in Table 1below. In this table, and Tables 2 to 4 below, yarn sizes are stated formonofilaments having generally circular cross-sections; but othercross-sectional shapes can also be used. Fabrics intended for one of thegrade designations below would each be woven using the distinct warpplatform appropriate for the particular grade designation. Table 1indicates three warp platforms for the three groups respectively, andthe corresponding optimized warp yarn sizes.

TABLE 1 Basis Weight Warp General Grade (gsm*) Range Yarn Size OptimizedWarp Designation of Product Range (mm) Yarn Size (mm)Packaging/Linerboard 80+ 0.15-0.35 0.22 Printing/Writing 35-80 0.10-0.170.15 Towel/Tissue 15-35 0.08-0.13 0.11 *= grams per square meter

In Table 1, a wide range of paper products have been grouped by basisweight into three general grade designations: packaging and linerboardwhich are generally heavier products and require a high basis weight ofabout 80 gsm or more; printing and writing grades such as newsprint,magazine and similar papers intended for the application of ink andwhich have a lower basis weight range of between about 35 and 80 gsm;and towel and tissue which are relatively light basis weight productsranging from about 15 to 35 gsm. Each of these products will require afabric the papermaking and mechanical properties of which are optimizedfor the manufacturing requirements and machine conditions to which theywill be exposed. As noted above, fabric manufacturers wouldconventionally produce differing fabrics for a much smaller range ofbasis weights, so that within each of the above general gradedesignations, multiple fabric designs would be used, each having adifferent warp platform, to satisfy a narrower basis weight range. Ithas now been found that fabric products can be grouped within e.g. thecategories identified in Table 1, so that a single warp platform can beused for each fabric within a specific group, i.e. utilizing one set ofwarp yarns in each of the PS and MS woven structures for the fabrics ofthe particular group, to satisfy the requirements of each grade.

If this is done, then the weft yarn size and knocking (number of weftyarns per unit length of fabric) used in combination with the warp willbe selected to correspond with the warp yarn sizes. For the sizes statedin Table 1 above, appropriate PS weft yarn sizes would generally rangefrom about 0.08 mm to about 0.50 mm, with the actual size and knockingbeing selected in combination with the warp yarn mesh, size andcross-sectional shape available. For example, a round cross-section warpyarn having a diameter of about 0.11 mm intended for a fabric for themanufacture of low basis weight products such as tissue would generallyutilize a weft yarn size of from about 0.08 mm to 0.20 mm at a PSknocking of from about 50 to 100 yarns/inch (19.7-39.4 yarns/cm).Selection of an appropriate weft yarn size, shape, material and knockingwill provide a fabric having the necessary physical and mechanicalproperties within the range appropriate for the product to be made. TheMS weft yarns can be selected to provide the required properties for theintended end use, and can be as large as required. The warp yarn sizerange in Table 1 would be appropriate for any of these fabric structuresand designs, and such fabrics could be woven on a loom provided withone, two or three beams as required.

The invention is based on the understanding that selection of a warpplatform, i.e. preferred mesh, warp size and cross-sectional shapeappropriate for a range of fabrics, is made by evaluating the mechanicalproperties requirements of the resulting fabrics in combination with thepapermaking properties of the fabric. The fabric must provide adequatephysical properties appropriate for the environment for which it isintended, which are primarily dictated by the elastic modulus of thewarp materials and the resulting stability (as dictated by the shearvalues of the fabric). Selection of appropriate weft yarncross-sectional shape and size, material composition and knocking thusbecome much more important variables that which will allow foradjustment of fabric properties to suit the intended end use of theproduct. Additional important mechanical properties include lateralcontraction (the narrowing of a fabric as it is tensioned) and fabriccaliper. These mechanical requirements are then considered incombination with the desired papermaking properties of the fabric. Oncea warp platform has been selected, the section of appropriate weft yarnshape, size, composition and knocking then becomes a process which willbe readily apparent to those skilled in the art.

Conventionally, a major constraint when changing from one product at onewarp size and mesh to another at a different warp size and mesh was thenecessity to match the new warp cross-sectional area to the old.Mechanical properties of a fabric are primarily determined by thecross-sectional area of the warp used in the fabric (e.g. for warp yarnshaving a circular cross-section, the total warp cross-sectional area inthe fabric will be πr²×mesh). When changing production from a fabricemploying a relatively larger warp size (e.g. 0.25 mm) to smaller (e.g.0.21 mm), the manufacturer would have to increase the mesh to ensure thesame amount of warp cross-sectional area was available to meet thetarget elastic modulus of the fabric.

It has been found that the use of high modulus warp yarn materials,particularly polyethylene naphthalate (PEN) and blends thereof such asare described for example in PCT/US2009/034850, or high moduluspolyethylene terephthalate (PET) yarns allows the use of smallerdiameter warp at lower mesh while still maintaining adequate elasticmodulus in the resulting fabric, so these materials are thusparticularly suitable for use in fabrics made according to theinvention. However, depending on the environment in which the fabricwill be used, and the intended end use requirements, other materials mayalso be suitable. If warp yarns having a smaller cross-sectional areacan provide adequate elastic modulus for the intended product, thengreater freedom is available for the selection of an appropriate weftyarn size and knocking which will, in turn, allow for a wider variety ofpaper grades to be manufactured using fabrics produced from the samewarp. Monofilaments formed from PEN may be more suited for use infabrics where the chosen warp yarn size is relatively small or which maybe subjected to higher than normally expected linear tensions. Yarnsmade from polymers such as polyetheretherketone (PEEK), polyphenylenesulphide (PPS), various polyamides or similar materials may also beused.

The chosen weft yarn can be any of the thermoplastic polymericmonofilaments or multifilaments currently employed in the manufacture ofindustrial textiles. While polymers such as PET and polybutyleneterephthalate (PBT), polyamides such as polyamide 6, 6/6, 6/10, 6/12,and blends of thermoplastic polyurethane and PET such as are describedin U.S. Pat. No. 5,169,711 or U.S. Pat. No. 5,502,120 may be suitable;others may be effective as well and the invention is not limited in thisway. Similarly, the weft yarns used in fabrics made according to thisinvention will generally have a substantially circular cross-sectionalshape, but they could also be generally rectangular, square, ovate orotherwise depending on the desired fabric properties and its intendedoperating environment.

Drainage area as well as other papermaking properties of the PSincluding air permeability, frame length, fiber support index (FSI) canbe adjusted by appropriate selection of weft yarn knocking, size andmaterials. Weft yarn used in the fabrics of this invention can be of anysize, shape or composition appropriate for the application. To meet ormatch fabric specifications (e.g. fiber support or drainage area) whenmoving from one warp size to another, it is necessary to adjust, i.e.increase or decrease, the knocking or the weft size. For example, alarger warp will reduce the drainage area; therefore, this must beaccommodated by decreasing the weft size to provide both adequatesupport for the papermaking fibers and drainage area. The weft yarnmaterial may also be changed to provide a monofilament which is eitherstiffer or more malleable, depending on the property change necessary tomatch specifications. Such adjustments to the weft yarn parameters wouldbe readily apparent to the person skilled in the art of manufacture ofthese industrial textiles.

Preferably, the warp yarn diameter should not be larger than about 0.5mm, but preferably will generally be in the range of 0.08 to 0.35 mm, asindicated in Table 1 above, and more preferably will be in the range of0.1 mm to 0.25 mm, so as to provide adequate PS surface properties andthe PS weft should not be smaller than the warp by a difference ofgreater than 0.1 mm to 0.05 mm, to ensure that on heatsetting the weftprovides sufficient crimp to the warp, to avoid the warp being undulystraight, which could lead to insufficient stability of the resultingfabric. Subject to this constraint, the weft can be as large asnecessary or practical to provide the required properties.

The following steps describe the method of this invention whereby aplurality of existing industrial fabric structures, in particular wovenpapermakers forming fabrics and similar textiles intended for industrialfiltration and conveying applications, each previously including warpyarns of differing size, shape or composition, and which conventionallyhave been woven using differing meshes and loom shedding arrangements(and thus previously woven using differing looms, or loom settings), cannow be woven using a single loom and warp platform to provide a textilehaving mechanical and papermaking properties very similar to thosepreviously supplied using multiple looms, settings and components.Industrial fabric structures that can be woven using a single loom andwarp platform include: single layer, semi duplex, double layer, extrasupport double layer, triple weft, standard triple layer, triple layersheet support binder, triple layer warp tie, and triple layer integratedsheet support binder fabrics. Fabric properties are subsequentlyadjusted to meet operational requirements by appropriate selection ofweft yarn materials and knocking.

In the following discussion, the term “warp platform” is used to referto the set of warp yarn parameters including: a) diameter (orcross-sectional area in the case of non-round cross-section yarns), b)material composition (e.g. the polymer from which the yarn is formed bythermoplastic extrusion process), c) warp yarn mesh as woven (i.e. thenumber of warp yarns per unit width in the textile as woven and prior toany subsequent treatment such as by heatsetting) and d) the number ofsheds in a single loom required to weave the chosen fabric structure.

Similarly, the term “single warp platform” is used to refer to thecombination of warp-related parameters for a group of differentindustrial textile structures, which using conventional methods wouldhave been woven using different warp platforms for each of the differenttextiles. The related terms “single warp platform product” and “singlewarp platform loom” refer respectively to industrial textiles wovenusing a single warp platform, and the loom on which they are or can bewoven.

Referring now to FIGS. 1A to 1C, the steps taken in an exemplaryembodiment of the invention, described here in relation to establishinga single warp platform for textiles for papermaking, are as follows.

Step 1: Select the intended target paper grade or basis weight for theproduct for which the textiles will be used (e.g. Tissue: 15-35 gsm;Printing: 35-80 gsm; Packaging/Linerboard: >80 gsm). The term “basisweight” in Table 1 above, and throughout the following discussion, hasthe meaning commonly assigned to it in the papermaking arts and refersto the mass per unit area of the finished paper product that is to bemade using the industrial textile.Step 2: Review the mechanical and papermaking properties of existingindustrial textile structures that are currently used or expected to beused in the manufacture of a cellulosic product for the target papergrade or basis weight, and which are intended to be consolidated into aSWP Platform, using the criteria of Table 1, so as to establish anappropriate group of fabrics. In Table 1, the warp yarns have asubstantially circular cross-section, which will generally be the shapeselected for a new SWP Product; however, the same process would be usedfor other cross-sectional yarn shapes by determining their projectedwidth on the PS. Through experimentation and experience, it has beenfound that the warp yarn diameters indicated below can be employedsuccessfully in industrial textile structures intended for use in theproduction of paper products having the indicated basis weights:Basis weight range >80 gsm: use 0.22 mm diameter warp yarnsBasis weight range 35-80 gsm: use 0.15 mm diameter warp yarnsBasis weight range 15-35 gsm: use 0.11 mm diameter warp yarnsStep 3: Determine the number of sheds used by looms to weave fabricscurrently intended for use for the target paper grades and basis weightslisted in Step 1, and the number of sheds which would be required forany new fabrics which would advantageously be included in the groupunder consideration, as identified in Step 2. Select an appropriatenumber of sheds to be provided. It has been found that previouslyexisting industrial textile structures woven according to 2, 3, 4, 6, 8,12, and 24 shed weave designs are most suitable for conversion to an SWPPlatform; however others are possible. A 24 shed loom is particularlyadvantageous as it can accommodate a wider range of existing industrialtextile structures than looms provided with differing sheddingarrangements, such as 20.Step 4: Select the different fabric structure types to be included inthe group, e.g. single layer, double layer, triple layer, and others aslisted above. From these fabric structure types, select those structuresfor which the weave designs will require a number of sheds which isequal to, or is an integer multiple of, the number of sheds selected inStep 3. For example, a 24 shed SWP loom can produce 2, 3, 4, 6, 8, 12and 24 shed weave designs, but cannot produce 5 or 7 shed designs.Step 5: From the fabrics identified in Step 4, select those with mesheswithin 20% (i.e. ±10%) of each other which, in addition, utilize warpyarn materials whose diameters (or projected widths on the PS of thefabric) are within ±25% of each other. It has been found that fabricswithin such range of each other will be particularly amenable to the SWPprocess, primarily because the mesh will determine, to a great extent,both the mechanical and papermaking properties of the resulting SWPfabric. The SWP Product must have sufficient modulus (i.e. MD strength),as well as air permeability, drainage and fiber support to enable themanufacture of the target paper grade. By selecting related fabrics forthe particular group (i.e. intended for the same general gradedesignation, such as is shown in Table 1) it is much easier toconsolidate the characteristics of several differing fabrics into one ora few having acceptable mechanical and papermaking properties for theintended end use.Step 6: From the set of target fabrics identified in Step 5, selectthose having total warp cross-sectional areas that are within about 30%(i.e. ±15%) of one another. As noted above, the total warpcross-sectional area=[(fabric mesh×warp yarn cross-sectional area)/unitwidth of fabric].Step 7: Select those target fabrics identified in Step 5 which have PSwarp fills that are within 10% (i.e. ±5%) of each other. As noted above,warp fill=warp yarn cross sectional area×mesh. Use the set of fabricsidentified in Step 5 to determine the PS warp fill of the new SWPproduct. The warp fill of the SWP Product should preferably be within±10% of the target fabrics identified in Step 6 whose platforms are tobe consolidated into a single SWP platform, and more preferably itshould be within ±5% of the target fabrics identified in Step 6. Thiswill allow the SWP Product to more easily produce the papermakingcharacteristics required.Step 8: Determine the ranges of concurrence for the fabrics identifiedand considered in each of Steps 6 and 7. From the set of fabricsidentified in each of those Steps, select those fabrics whose total warpcross-sectional areas are between about ±15% of each other (Step 6), andwhose PS warp fills are within about ±5% of each other (Step 7). Thisconcurrence identifies the range of warp diameters and meshesappropriate for the new SWP Product that will satisfy both the basicmechanical and drainage requirements of the fabrics intended for thetarget basis weight range (i.e. paper grade), and which will also fitwithin the construction parameters of existing and proposed industrialtextile structures.Step 9: Determine optimal warp yarn diameter and mesh for SWP Product byweighting fabric properties relative to their importance to the targetpaper grade, including at least:

-   -   a) air permeability,    -   b) maximum frame length, and    -   c) PS drainage area.

The determination is performed by estimating the effect that warpdiameter and mesh will have on the mechanical and papermaking qualitiesof the SWP Product. This can most easily be done by assigning aweighting factor (e.g. Low, Medium, High) to the importance of eachproperty for the target basis weight and paper grade. Table 2 belowprovides an example of such weighting for various fabric properties usedin fabrics intended for Packaging grades (Basis weight >80 gsm) andwhich are woven with warp yarns having circular cross-sections.

TABLE 2 Fabric Property Weightings for SWP Products Intended forPackaging Grades Weighting/ Property Warp Diameter Mesh Comments AirPermeability Smaller is better Lower is better High Seam Strength Largeris better Higher is better High Shear Stability Larger is better Higheris better High Stiffness Larger is better Higher is better High WeftCount Range Smaller is better Lower is better High Cloth Caliper Smalleris better No effect Medium Drainage Area Smaller is better Lower isbetter Medium Frame Length Smaller is better Lower is better MediumFibre Support Index Smaller is better Higher is better Low SheetSmoothness Smaller is better Higher is better Low

In Table 2 above, there are five parameters with High weightings; threeof the five support the choice of larger warp diameters and higher meshcounts for this fabric application (Shear Stability, Stiffness & SeamStrength) while the remainder support the choice of smaller warpdiameters and lower mesh counts. The choices for the SWP Productintended for the manufacture of paper products having this relativelyhigh basis weight lean slightly towards choosing as large a warpdiameter as possible with as high a warp mesh as possible. It should benoted that a small warp diameter and low mesh are indicated for all ofair permeability, frame length and drainage area, but the latter twoproperties are assigned a weighting of “Medium” importance, thus leadingthe manufacturer towards a larger warp diameter and higher mesh count inthe resulting SWP fabric due to the relative importance of theseproperties to the manufacture of the target paper grade.

After Step 9, two parallel groups of steps are conducted, the firstgroup (Steps 10A, 11A) relating to providing and setting up the warpyarns on the loom, and the second group (Steps 10B, 11B and 12) relatingto selecting the fabric to be woven, and determining the weft parametersrequired. These two groups of steps can be performed in any order orconcurrently.

Step 10A: Provide an industrial loom (the “SWP loom”) having the numberof sheds determined as appropriate in Step 3.Step 11A: Provide the SWP loom with a set of warp yarns having the sizeand mesh determined at Step 9. The warp yarns are mounted on at leastone back beam, the warp yarns being threaded through the reed openingsin the heddles of the loom to provide a desired mesh, and the heddlesarranged to provide the required number of sheds. The warp yarns may bethreaded at a density of 1, 2, 3 or as many as 4 yarns per dent (reedopening) in the reed. The SWP Loom is configured according to thedesired SWP platform, enabling the fabric manufacturer to consolidatethe production of a plurality of industrial fabric structures havingsimilar mesh (which would previously have been woven on multiple looms)onto one loom.Step 10B: Select a fabric structure type, e.g. single layer, triplelayer, for the first fabric to be woven.Step 11B: Select a weave design for the first fabric to be woven, fromexisting or new designs.Step 12B: Determine weft yarn diameters and knocking for the firstfabric, having regard to the warp yarn size, mesh and totalcross-sectional area selected for the SWP Product, to obtain thecharacteristics required for the fabric to be woven, to achieve the bestcompromise of fabric properties.Step 13: Install weft yarn material selected in Step 12B into the loom,and adjust loom to provide appropriate knocking as determined in Step12B.Step 14: Weave and finish the first fabric, including heatsetting andseaming.Step 15: Select a fabric structure type for a second fabric to be woven,in the same manner as for the first fabric in Step 10B.Step 16: Select a weave design for the second fabric to be woven, fromexisting or new designs.Step 17: Determine weft yarn diameters and knocking for the secondfabric in the same manner as for the first fabric in Step 12B.Step 18: Install weft yarn material selected in Step 17 into the loom,and adjust loom to provide appropriate knocking as determined in Step17.Step 19: Weave and finish the second fabric, including heatsetting andseaming.Step 20: Repeat Steps 15 to 19 for third and subsequent fabrics.

Experimental Trials

Several fabrics were woven using the methods of this invention asexpressed above and the results are presented in Tables 3 and 4 below inwhich SWP Products were made and their properties compared to comparableexisting industrial textile structures. In Table 3 below, two existingindustrial textile structures, one an extra support double layer (ESDL)fabric, and the other a triple layer sheet support binder (SSB) fabric,each of which were previously woven on separate looms, have beenconverted into SWP Products by means of the method of this invention.

TABLE 3 Comparison of Properties of Existing Industrial TextileStructures and SWP Products Existing SWP Existing SWP Structure ProductStructure Product Sample No. 1 2 3 4 Weave Type ESDL* ESDL* SSB** SSB**No. Sheds 8 24 24 24 Mesh (as woven) 98 112 112 112 Mesh (as heatset)112 124 126 126 Yarn Count (No./in.) Total (heatset) 112 × 105 124 × 105126 × 108 126 × 108 Paper Side 112 × 70  124 × 70  63 × 54 63 × 54Machine Side 112 × 35  124 × 35  63 × 36 63 × 36 Warp Fill (%) 110 10750 55 Yarn Diameters (mm) Paper Side MD 0.25 0.22 0.20 0.22 Machine SideMD 0.27 0.22 Paper Side CD 0.26 0.25 0.19 0.18 Paper Side Tie 0.15 0.170.19 0.18 Strand Machine Side CD 0.45 0.45 0.40 0.40 FabricCharacteristics Paper Side 40.0% 45.9% 30.0% 28.0% Drainage Area FramesCount 1470/in.² 1085/in.² 3402/in.² 3402/in.² Fibre Support Index 95 88114 114 (F.S.I) Maximum Frame 0.576 0.556 0.280 0.290 Length (mm) AirPermeability 370 cfm 365 cfm 450 cfm 470 cfm @125 Pa @125 Pa @125 Pa@125 Pa New Caliper (in.) 0.050 0.050 0.051 0.048 Drainage Index 21.020.2 24.3 25.4 Elastic Modulus 11400 pli 12000 pli 9800 pli 8600 pli*ESDL = Extra Support Double Layer **SSB = Sheet Support Binder

Table 3 provides a comparison between two known textile products(Samples 1 and 3), and textiles of the same structural type made usingan SWP platform (Samples 2 and 4). Samples 1 and 2 were woven as extrasupport double layer fabrics, and it can be seen from Table 3 that theirmechanical and papermaking properties and characteristics are closelysimilar, despite the changes in the warp and weft yarn parametersresulting from using the SWP.

Similarly, Samples 3 and 4, each woven as triple layer sheet supportbinder fabrics, can be seen to be closely similar. Thus each of Samples2 and 4, produced from an SWP, can be seen to be acceptable replacementsfor Samples 1 and 3.

TABLE 4 Comparison of Properties of Existing Products and SWP ProductsExisting SWP Existing SWP Structure Product Structure Product Sample No.5 6 7 8 Weave Type ESDL ESDL SSB SSB No. Sheds 8 24 24 24 Mesh (aswoven) 98 112 112 112 Mesh (as heatset) 112 122 126 128 Yarn Count(No./in.) Total (heatset) 112 × 87 122 × 90 126 × 108 128 × 107 PaperSide 112 × 58 122 × 60 63 × 54 64 × 53 Machine Side 112 × 29 122 × 30 63× 36 64 × 35 Warp Fill (%) 110 106 50 55 Yarn Diameters (mm) Paper SideMD 0.25 0.22 0.20 0.22 Machine Side MD 0.27 0.22 Paper Side CD 0.25 0.250.19 0.20 Paper Side Tie 0.16 0.16 0.19 0.20 Strand Machine Side CD 0.400.40 0.35 0.35 Fabric Characteristics Paper Side 45.3% 45.1% 30.0% 25.9%Drainage Area Frames Count 1218/in.² 1373/in.² 3402/in.² 3408/in.² FibreSupport Index 82 85 114 114 (F.S.I) Maximum Frame 0.716 0.687 0.2800.277 Length (mm) Air Permeability 450 cfm 460 cfm 455 cfm 470 cfm @125Pa @125 Pa @125 Pa @125 Pa New Caliper (in.) 0.045 0.042 0.047 0.050Drainage Index 21.2 22.4 24.6 25.0 Elastic Modulus 11,800 9,600 10,8009,800

Table 4 shows a similar comparison to that of Table 3, in relation totwo further known textile products (Samples 5 and 7), and two textilesof the same structural type using an SWP platform (Samples 6 and 8).Samples 5 and 6 were woven as extra support double layer fabrics, andSamples 7 and 8 were woven as triple layer sheet support binder fabrics.

As in the case of the SWP fabrics of Table 3, for each of the SWPfabrics of Table 4 their mechanical and papermaking properties andcharacteristics are closely similar, despite the changes in the warp andweft yarn parameters resulting from using the SWP. Thus each of Samples6 and 8, produced from an SWP, can be seen to be acceptable replacementsfor Samples 5 and 7.

It is important to note that both the ESDL and SSB weft tied SWPproducts of Samples 2, 4, 6 and 8 were woven using the same warp yarnsize and mesh (0.22 mm warp diameter and 112 yarns/in. mesh). However,the mesh (as heatset) of the ESDL and the SSB fabrics made using the SWPProcess are slightly different. The heatset mesh of the ESDL fabricswere 124 (Sample 2) and 122 (Sample 6) while that of the SSB fabricswere 126 (Sample 4) and 128 (Sample 8), even though all fabrics werewoven using the same mesh of 112. The reason for this is that thesedesigns require somewhat different heatsetting parameters in order tooptimize their mechanical properties and typically the degree of widthreduction during heatsetting is about 2-3% higher for the SSB fabric dueto the differences between its structure and that of the ESDL fabric.

A primary control variable for the heatsetting process is the totalwidth shrinkage. Depending on the weave structure and intended end useof the fabric, differing width shrinkage targets of from about 5% to 15%may be required to achieve optimal fabric properties in the SWP Product.Therefore, although the as woven mesh of two fabrics may be the same,the finished (heatset) fabric mesh may differ by an amount in accordancewith the 5% to 15% width shrinkage targets.

Thus, the SWP Process has resulted in the ability to consolidate two ormore previously different warp platforms with differing warp yarn sizesinto a single mesh and warp size, which eliminates the need for majorchanges to the loom set-up. This results in significantly reduced downtime of the loom, in changing fabric production between the differentfabrics in the group to which the platform is applicable.

As discussed above, the method of this invention is directed to loomsequipped with at least one back beam; it can also be used in loomsequipped with two or three back beams so as to accommodate differingwarp path lengths in the fabric due to differing weave designs on eachof the paper and machine side surfaces of the fabric. Further, theinvention is directed to fabric designs which are woven using any numberof sheds in the loom as are required to weave the chosen design; howeverfabric designs woven according to patterns requiring 2, 3, 4, 5, 6, 8,10, 12, 16, 20, 24, 32, 36 and 48 sheds are particularly preferred.However, the invention is in no way limited to numbers of sheds requiredto weave a given fabric design, or to fabric structure (i.e. single,double, triple layer, etc.). The invention is also directed at fabricswhose structure requires the use of two warp yarn systems, such astriple layer sheet support binder fabrics and warp tie fabrics where thesize and mesh of the warp on one fabric surface is different from thatused on the other, however it is not so limited and has applicability toany industrial textile structure.

1-38. (canceled)
 39. A method of manufacturing woven fabrics from warpyarns and weft yarns for industrial uses, the method comprising thesteps of: (a) identifying optimal fabric characteristics to correspondwith at least one selected industrial use, and for each selectedindustrial use identifying a plurality of different suitable fabricconstructions, to comprise at least one group of fabrics for thatselected industrial use; (b) selecting a set of shedding options for aloom and providing the loom with a shedding arrangement to provide theselected shedding options; (c) selecting a first group from the at leastone group of fabrics and identifying selected fabric properties toproduce the optimal fabric characteristics for the first group; (d)identifying a single set of optimal parameters for warp yarns to providethe selected fabric properties identified in step (c) for all of thefabrics of the first group of fabrics; (e) selecting a fabricconstruction and a weave design for each fabric of the first group; (f)installing warp yarns on the loom to correspond with the single set ofoptimal parameters identified in step (d); (g) selecting a first fabricof the first group, identifying properties for weft yarns to correspondwith a first weave design for the first fabric, setting the loom tocorrespond with the first weave design, and weaving the first fabricaccording to the first weave design; and (h) selectively repeating step(g) for selected other ones of the fabrics in the first group.
 40. Amethod according to claim 39, wherein the identifying optimal parametersin step (d) comprises the steps of (d.1) identifying optimal warp yarnsizes for the intended end use; (d.2) determining fabric mesh; (d.3)determining cross-sectional shape and size of the warp yarns; (d.4)determining total warp cross sectional area per unit width of thefabrics; and (d.5) determining paper side warp fill.
 41. A methodaccording to claim 39, wherein the identifying properties for weft yarnsin step (g) comprises determining weft yarn size and knocking measuredas number of weft yarns per unit length of the fabric
 42. A methodaccording to claim 39, wherein step (b) comprises providing a loomequipped with a number of back beams selected from one, two and three.43. A method according to claim 42, wherein the loom is equipped withtwo back beams.
 44. A method according to claim 39, wherein in step (f)the warp yarns are constructed of a material selected from polyethyleneterephthalate (PET), polyethylene naphthalate (PEN),polyetheretherketone (PEEK), polyphenylene sulphide (PPS) and blends andcopolymers thereof.
 45. A method according to claim 39, wherein in step(g), the weft yarns are constructed of a material selected from PET,polybutylene terephthalate (PBT), a polyamide selected from polyamide 6,6/6, 6/10, and 6/12, and blends of thermoplastic polyurethane and PET.46. A method according to claim 39, wherein step (a) comprisesdetermining a maximum of four groups of fabrics.
 47. A method accordingto claim 39, wherein the identifying properties in step (g) comprisesselection of adjustable properties selected from at least one of weftyarn material, cross-section shape, size and knocking.
 48. A methodaccording to claim 47, wherein the selection of adjustable properties isperformed to correspond with product criteria for a paper product to bemanufactured using the first fabric, wherein the product criteriacomprise at least one of the basis weight and the paper grade of thepaper product.
 49. A method according to claim 39, wherein theidentified optimal parameters for warp yarns comprises warp sizes inranges between 0.08 mm and 0.50 mm.
 50. A method according to claim 49,wherein the identified optimal parameters for warp yarns comprises warpsizes in ranges between 0.1 mm and 0.35 mm.
 51. A method according toclaim 39, wherein the selecting a weave design in step (e) comprisesmodifying an existing design.
 52. A method according to claim 39,wherein the selecting a weave design in step (e) comprises preparing anew design.
 53. A method according to claim 39, wherein the sheddingoptions in step (b) comprise using an integer multiple of 2, 3, 4, 6, 8,12 or 24 sheds on the loom.
 54. A method according to claim 53, whereinthe shedding arrangement requires 24 sheds.
 55. A method according toclaim 39, wherein the selecting fabric construction of step (e)comprises selecting a type from single layer fabrics, semi-duplexfabrics, double layer fabrics, extra support double layer fabrics,triple weft fabrics, standard triple layer fabrics, triple layer sheetsupport binder fabrics, triple layer warp tie fabrics, and triple layerwarp integrated sheet support binder fabrics.
 56. A method according toclaim 55, wherein the selecting fabric construction of step (e)comprises selecting a type from extra support double layer fabrics,triple layer sheet support binder fabrics, triple layer warp tiefabrics, and triple layer warp integrated sheet support binder fabrics.57. A method according to claim 56, wherein the selecting a weave designof step (e) comprises selecting a design requiring two systems of warpyarns, wherein the warp yarn material, size, cross-sectional shape andmesh in each system is substantially the same.
 58. A method according toclaim 39, wherein the warp yarns are polymeric monofilaments.
 59. Amethod according to claim 39, wherein the warp yarns are polymericmultifilaments.
 60. A method according to claim 58, wherein the warpyarns are selected from one of plied polymeric monofilaments and cabledpolymeric monofilaments.
 61. A method according to claim 59, wherein thewarp yarns are selected from one of plied polymeric multifilaments andcabled polymeric multifilaments.
 62. A method according to claim 48,wherein the paper product is selected from a member of one of threegroups of paper products, wherein a first group has a basis weight in arange between 15 and 35 gsm, a second group has a basis weight in arange between 35 and 80 gsm, and a third group has a basis weightgreater than 80 gsm.
 63. A method according to claim 48, wherein thepaper product is selected from a member of one of three groups of paperproduct grades, wherein a first group comprises towel and tissue, asecond group comprises printing and writing, and a third group comprisespackaging and linerboard.
 64. A method according to claim 39 wherein thePS weft yarns have a diameter in a range of between 0.08 mm and 0.50 mm.65. A method according to claim 64, wherein the diameter of the PS weftyarns is in a range of between 0.1 mm and 0.35 mm.
 66. A methodaccording to claim 64, wherein the PS weft yarns are polymericmonofilaments.
 67. A method according to claim 64, wherein the PS weftyarns are polymeric multifilaments.
 68. A method according to claim 66,wherein the PS weft yarns are selected from one of plied polymericmonofilaments and cabled polymeric monofilaments.
 69. A method accordingto claim 67, wherein the PS weft yarns are selected from one of pliedpolymeric multifilaments and cabled polymeric multifilaments.
 70. Amethod according to claim 64 wherein the warp yarns have a diameterwhich exceeds the diameter of the PS weft yarns by less than 0.10 mm.71. A method according to claim 70, wherein the warp yarns have adiameter which exceeds the diameter of the PS weft yarns by less than0.05 mm.
 72. A method according to claim 39, further comprising afterstep (g) the step of (g.1) heatsetting the first fabric.
 73. A group ofat least two industrial textiles, wherein each industrial textilecomprises a woven structure of polymeric warp and weft yarns, wherein(i) the woven structure of each industrial textile is different from thewoven structure of each other industrial textile in the group, and isselected from one of a single layer, semi duplex, double layer, extrasupport double layer, triple weft, standard triple layer, triple layersheet support binder, triple layer warp tie, and triple layer integratedsheet support binder fabric construction; (ii) the warp yarns have warpyarn properties comprising size, shape, polymeric composition, andtogether have a mesh value; and (iii) the warp yarn properties and meshvalue of each industrial textile are substantially identical to the warpyarn properties and mesh value of each other industrial textile in thegroup.
 74. A group of industrial textiles according to claim 73, whereinthe composition of the warp yarns comprises polyethylene terephthalate(PET), polyethylene naphthalate (PEN), polyetheretherketone (PEEK),polyphenylene sulphide (PPS) and blends and copolymers thereof.
 75. Agroup of industrial textiles according to claim 73, wherein eachindustrial textile is woven according to a pattern having a loomrequirement for a number of sheds selected from an integer multiple of2, 3, 4, 6, 8, 12 and
 24. 76. A group of industrial textiles accordingto claim 73, wherein each industrial textile is woven according to apattern having a loom requirement for a number of sheds selected from aninteger multiple of 5, 7, 9, 11, 13, 17, 19 and 23.